Full face respirator

ABSTRACT

A full face respirator comprising a mask (10) having a transparent viewing portion (12) and a port portion (16), and exhalation port (22) disposed in said port portion (16), a face seal configured (14) to seal the mask (10) over a wearer&#39;s eyes, nose and mouth, in use, and an orinasal assembly (2) comprising a flexible, cup-shaped orinasal (2) having an orifice (2a) and being configured to fit over a wearer&#39;s nose and mouth, in use; wherein the orinasal assembly (2) further comprises a generally tubular connecting portion (24), integrally formed with and extending outwardly from the periphery of said orifice (2a), said connection portion (24) being shaped and configured to extend through said exhalation port (22) from the inner region to the outer region of the mask (10) and including an exhalation valve mount (28) for receiving a one-way exhalation valve (4).

FIELD OF THE INVENTION

This invention relates generally to a full face respirator for providinga user with a breathable air supply within an environment that may becontaminated with harmful or irritating gases or other substances.

BACKGROUND OF THE INVENTION

WO98/13103 describes a full face respirator comprising a face shield,including a transparent viewing portion and a face seal for sealing theface shield over a user's face, in use. The face shield comprises upperand lower frame members, the lower frame member including a port portionlocated below the transparent viewing portion. The port portion includesa pair of air intake ports, each having a connector for receiving afilter cartridge, and a central exhalation port. A nose cup or orinasalis provided, which fits over a user's nose and mouth in use and includesa central orifice having circumferential connecting regions on the innerrim thereof. The full face respirator further comprises a centre adaptercomprising a base having a generally cylindrical end portion on which agasket is fitted. The base is configured to receive an exhalation valve,and connecting members are provided on the outer wall of the cylindricalend portion. When it is required to assemble the device, the cylindricalend portion is inserted through the central exhalation port (to theinner region of the mask) and is received within the central orifice ofthe orinasal, the connecting members of the cylindrical end portion ofthe base thus engaging with the connecting regions on the inner rim ofthe central orifice of the orinasal to releasably connect the base(including the exhalation valve) to the orinasal at the inner region ofthe mask such that the exhalation valve is located outside the maskagainst the periphery of the central exhalation port. A protective coveris removably mounted over the exhalation valve.

Full face respirators of this type have been in widespread use for manyyears by, for example, firefighters, military personnel andindustrial/construction operatives, where a clean air supply is requiredbecause the surrounding environment may be contaminated with toxicsubstances. In addition to supplying a clean air supply, such full facerespirators include a mask that provides a seal around the entire facewith a flexible face seal to protect both the eyes and the face from thepotentially toxic substances.

However, there are a number of issues associated with known full facerespirators. Firstly, most full face respirators, including those of thetype described above, are designed to be disassembled for cleaning andmaintenance purposes. However, re-assembling such devices for use can bedifficult to achieve efficiently. The internal connecting or mountingpoints in the rim of the orinasal, and the flexibility of the orinasalstructure at the location of its central orifice, can make the task ofre-connecting the base (and exhalation valve assembly) to the orinasalfiddly. This process usually results in repeated deformation of theorinasal, which in turn can lead to premature failure. Even prior tocomplete failure thereof, it may become warped, leading to a loss of itscorrect and intended shape, which results in poor face fitment,increased breathing resistance and/or greater risk of inward leakage.

It is an object of aspects of the present invention to address at leastsome of these issues.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the present invention, there isprovided a full face respirator comprising a mask having a transparentviewing portion and a port portion, an exhalation port disposed in saidport portion, a face seal configured to seal the mask over a wearer'seyes, nose and mouth, in use, and an orinasal assembly comprising aflexible, cup-shaped orinasal having an orifice and being configured tofit over a wearer's nose and mouth, in use; wherein the orinasalassembly further comprises a generally tubular connecting portion,integrally formed with and extending outwardly from the periphery ofsaid orifice, said connecting portion being shaped and configured toextend through said exhalation port from the inner region to the outerregion of the mask and including an exhalation valve mount for receivinga one-way exhalation valve.

Thus, the connection between the orinasal and the mask at the locationof the exhalation valve is effected simply by inserting the connectingportion through the exhalation port, from the inner region to the outerregion of the mask, eliminating the internal connecting points andmaking the re-assembly process less fiddly in comparison with prior artdevices.

In an exemplary embodiment, a sealing gasket is provided around theouter wall of the connecting portion, adjacent to the orifice of theorinasal, for sealing the orinasal against the periphery of theexhalation port.

The connecting portion and the inner peripheral wall or rim of theexhalation port may comprise integral cooperative connecting members forremovably affixing the orinasal assembly to the exhalation port (and,therefore, the mask). The connecting members may comprise male andfemale portions respectively of a twist bayonet connection mechanismbetween the connecting portion and the exhalation port. The male andfemale portions of the twist bayonet connection mechanism may beintegrally formed in or on the inner wall/rim of the exhalation port andthe outer wall of the connecting portion of the orinasal assemblyrespectively. In an exemplary embodiment, the female portion of thetwist bayonet connection mechanism may be integrally formed on the outerwall of the connecting portion of the orinasal assembly and the maleportion thereof may be formed on the inner wall or rim of the exhalationport. This type of connection mechanism, provided within the exhalationport and configured to engage with the connecting portion of theorinasal assembly, is considered particularly beneficial as it providesa positive and intuitive connection mechanism between the parts,resulting in increased ease of disassembly for cleaning and subsequentre-assembly for use.

In an exemplary embodiment, the connecting portion of the orinasalassembly is substantially rigid, and the cup-shaped orinasal isresiliently flexible (to provide a good and comfortable seal over theuser's nose and mouth). The rigidity of the connecting portion makes thedisassembly and subsequent assembly processes much easier and lessfiddly, and avoids undue deformation of the cup-shaped orinasal, thuspreventing warping and premature failure thereof. The connecting portionmay, for example, comprise a moulded hard polypropylene (PP) copolymer(or similar), with the female portion of the twist bayonet connectionmechanism being integrally moulded thereon, and the cup-shaped orinasalmay be formed of a flexible rubber (e.g. Thermoplastic Polyurethane orTPU), with which the connecting portion is overmoulded. As a result, therespirator provides a more robust and solid assembly, compared withprior art devices, and the orinasal body retains its correct andintended shape, irrespective of repeated disassembly and re-assembly,thus providing a better face fitment, lower breathing resistance andless inward leakage over time.

In an exemplary embodiment, the port portion of the respirator maycomprise at least one, and more preferably two, air intake ports, eachair intake port comprising a connector for removably receiving thereon afilter cartridge assembly. The cup-shaped orinasal may comprise at leastone aperture or opening adjacent the or each air intake port, when therespirator is assembled for use. The at least one aperture may havemounted or formed therein an inhalation valve mount for receivingthereon a one-way inhalation valve. The respirator may also include astrap or harness assembly for securing the mask over a user's face inuse. The harness or strap assembly may be removably connected to themask.

In accordance with a second aspect of the present invention, there isprovided an orinasal assembly for a full face respirator substantiallyas described above, comprising a flexible, cup-shaped orinasal having anorifice and being configured to fit over a wearer's nose and mouth, inuse; wherein the orinasal assembly further comprises a generallytubular, substantially rigid connecting portion, integrally formed withand extending outwardly from the periphery of said orifice, saidconnecting portion including an exhalation valve mount for receiving aone-way exhalation valve.

In accordance with a third aspect of the present invention, there isprovided a kit of parts for a full face respirator, comprising anorinasal assembly substantially as described above, a mask having atransparent viewing portion and a port portion, an exhalation portdisposed in said port portion, a face seal configured to seal the maskover a wearer's eyes, nose and mouth, in use, said connecting portion ofsaid orinasal assembly being shaped and configured to extend throughsaid exhalation port from the inner region to the outer region of themask and including an exhalation valve mount for receiving a one-wayexhalation valve, wherein a connection mechanism is provided in or onthe connecting portion of the orinasal assembly and or the exhalationport to releasably affix the orinasal assembly to the mask.

These and other aspects of the present invention will become apparentfrom the following specific description.

BRIEF DESCRIPTION OF THE DRAWINGS

An embodiment of the present invention will now be described, by way ofexample only, and with reference to the accompanying drawings, in which:

FIG. 1 is a schematic front perspective view of a full face respiratoraccording to an exemplary embodiment of the present invention, whenassembled for use; and

FIG. 2 is an exploded view of the full face respirator of FIG. 1,excluding the filter cartridges, illustrating the manner in which therespirator can be disassembled.

DETAILED DESCRIPTION

Referring to FIGS. 1 and 2 of the drawings, a full face respiratoraccording to an exemplary embodiment of the present invention comprisesa face shield or mask 10, including a transparent viewing portion 12 anda face seal 14 for sealing the mask 10 over a user's face, in use. Themask 10 comprises a port portion 16 located below the transparentviewing portion 12 when viewed from a front elevation (when therespirator is oriented for use). The port portion 16 includes a pair ofintake ports 18 (only one can be seen in FIG. 2), each having aconnector region 18 a for receiving a filter cartridge 20, and agenerally central exhalation port 22.

A nose cup or orinasal 2 is provided, which fits over a user's nose andmouth, in use, and includes a central orifice defined by peripheral rim2 a. The orinasal 2 is formed of a flexible rubber material, such asThermoplastic Polyurethane (TPU) although the present invention is notnecessarily strictly limited in this regard. The orinasal 2 comprises anintegral connecting portion 24, comprising a generally tubular,substantially rigid member that extends outwardly from the peripheralrim 2 a of the orinasal orifice. The connecting portion is moulded of ahard plastic material, such as hard polypropylene (PP) copolymner,although the present invention is not necessarily strictly intended tobe limited in this regard. The hard plastic connecting portion 24 is, ina preferred exemplary embodiment of the present invention, overmouldedwith the flexible rubber orinasal orifice 2 a to provide a robust andsolid assembly.

The outer wall of the connecting portion 24 includes integrally mouldedfemale connecting regions 26. In the illustrated example, three suchfemale connecting regions 26 are provided (although only one can be seenin FIG. 2 of the drawings): two being on diametrically opposing sidelocations on the outer wall of the connecting portion, and a third beinglocated between them on the lower wall of the connecting portion 24(when the respirator is oriented for use).

An exhalation valve frame member 28 is integrally moulded or otherwisemounted within the tubular connecting portion 24, adjacent to, andconcentric with, the orinasal orifice 2 a. The exhalation valve framemember 28 comprises a generally circular, hard plastic outer rim and aconcentric inner circular portion having a small central aperture.Radial ribs extend between the outer rim and the inner circular portion.A one-way exhalation valve 4, in the form of a flexible diaphragm, ismounted within the connecting portion 24 by inserting a pin 4 a thereofthrough the small central aperture in the exhalation valve frame member28.

A gasket 3 (or “o-ring”), which may be formed of any suitableresiliently flexible material such as rubber or silicone, is mountedover the connecting portion 24 and sits against the proximal endthereof, adjacent the orinasal orifice 2 a.

In order to assemble the respirator, the connecting portion 24,including the exhalation valve 4 and the gasket 3, is inserted throughthe exhalation port 22 of the mask 10 from the rear to the front (whenthe respirator is oriented for use). The inner wall of the exhalationport 22 is integrally formed with three male connecting regions 22 a(only two can be seen in FIG. 2), which correspond in relative locationto the female connecting regions 26 on the connecting portion 24. Itwill be appreciated that the outer diameter of the connecting portion 24is substantially the same as (or very slightly smaller than) the innerdiameter of the exhalation port 22, such that the connecting portion 24can be inserted into the exhalation port 22 in a snug fit and, due tothe slightly raised male connector regions 22 a, it can only be insertedthrough the exhalation port 22 if the female connector regions 26 on theconnecting portion 24 are aligned with the male connector regions 22 aon the inner wall of the exhalation port 22. The female connectingregions 26 on the connecting portion 24 and the male connector regions22 a on the inner wall of the exhalation port 22, together, form a twistbayonet connection mechanism between the connecting portion 24 and theexhalation port 22. Thus, once the connecting portion 24 is fullyinserted through the exhalation port 22, it can be twisted relativethereto to engage the female and male connecting regions 26, 22 a andlock the orinasal assembly to the mask 10. Of course, in alternativeexemplary embodiments, the female connecting regions may be provided onthe inner wall of the exhalation port 22 and the male connector regionsmay be provided at corresponding locations on the outer wall of theconnecting portion 24. Alternative suitable connection mechanisms mayalso be envisaged, and will be known to a person skilled in the art.

A cover 7. Having opening s7 a therein, is removably mounted (e.g. in asnap fit) over the front of the exhalation port 22 to protect theexhalation valve 4 and prevent the ingress of particulate matter fromthe external environment.

The orinasal 2 comprises a pair of intake apertures 30, one on each sideof the central orifice 2 a (only one intake aperture can be seen in theview of FIG. 2). An inhalation valve frame member 32 is moulded orotherwise mounted within each of the intake apertures 30, and eachinhalation valve frame member again comprises a pair of radiallyspaced-apart concentric circular members, with a small central apertureand radial ribs extending between the circular members. A one-wayinhalation valve 34, in the form of a flexible diaphragm, is mounted ineach intake aperture 30 by inserting a pin 32 a thereof through thesmall central aperture of a respective inhalation valve frame member 32.The outer rim 30 a of each intake aperture 30 is configured to engagewith a respective intake port 18 in the mask 10 to define a sealed airflow path, in use, between the inside of the orinasal 2 and therespective filter cartridge 20.

A harness or strap 6 is removably affixed to the mask 10 (at four points5 a, only three shown in the view of FIG. 2) by means of harness clips5, to enable the respirator to be secured to a user's head in use.

It will be apparent to a person skilled in the art, from the foregoingdescription, that modifications and variations can be made to thedescribed embodiments without departing from the scope of the inventionas defined by the appended claims.

1. A full face respirator comprising a mask having a transparent viewingportion and a port portion, an exhalation port disposed in said portportion, a face seal configured to seal the mask over a wearer's eyes,nose and mouth, in use, and an orinasal assembly comprising a flexible,cup-shaped orinasal having an orifice and being configured to fit over awearer's nose and mouth, in use; wherein the orinasal assembly furthercomprises a generally tubular connecting portion, integrally formed withand extending outwardly from the periphery of said orifice, saidconnecting portion being shaped and configured to extend through saidexhalation port from the inner region to the outer region of the maskand including an exhalation valve mount for receiving a one-wayexhalation valve.
 2. A full face respirator according to claim 1,wherein a sealing gasket is provided around the outer wall of theconnecting portion, adjacent to the orifice of the orinasal, for sealingthe orinasal against the periphery of the exhalation port.
 3. A fullface respirator according to claim 1, wherein the connecting portion andthe inner peripheral wall or rim of the exhalation port compriseintegral cooperative connecting members for removably affixing theorinasal assembly to the exhalation port.
 4. A full face respiratoraccording to claim 3, wherein the connecting members comprise male andfemale portions respectively of a twist bayonet connection mechanismbetween the connecting portion and the exhalation port.
 5. A full facerespirator according to claim 4, wherein the male and female portions ofthe twist bayonet connection mechanism are integrally formed in or onthe inner wall/rim of the exhalation port and the outer wall of theconnecting portion of the orinasal assembly respectively.
 6. A full facerespirator according to claim 1, wherein the connecting portion of theorinasal assembly is substantially rigid, and the cup-shaped orinasal isresiliently flexible.
 7. A full face respirator according to claim 6,wherein the connecting portion comprises a moulded hard polypropylene(PP) copolymer and the cup-shaped orinasal is formed of a flexiblerubber material with which the connecting portion is overmoulded.
 8. Afull face respirator according to claim 1, wherein the port portion ofthe respirator comprises at least one air intake port comprising aconnector for removably receiving thereon a filter cartridge assembly.9. A full face respirator according to claim 8, wherein the cup-shapedorinasal comprises at least one aperture or opening adjacent the or eachair intake port, when the respirator is assembled for use.
 10. A fullface respirator according to claim 9, wherein the at least one aperturehas mounted or formed therein an inhalation valve mount for receivingthereon a one-way inhalation valve.
 11. A full face respirator accordingto claim 1, further comprising a strap or harness assembly for securingthe mask over a user's face in use.
 12. A full face respirator accordingto claim 11, wherein the harness or strap assembly is removablyconnected to the mask.
 13. An orinasal assembly for a full facerespirator according to claim 1, comprising a flexible, cup-shapedorinasal having an orifice and being configured to fit over a wearer'snose and mouth, in use; wherein the orinasal assembly further comprisesa generally tubular, substantially rigid connecting portion, integrallyformed with and extending outwardly from the periphery of said orifice,said connecting portion including an exhalation valve mount forreceiving a one-way exhalation valve.
 14. A kit of parts for a full facerespirator, comprising an orinasal assembly according to claim 13, amask having a transparent viewing portion and a port portion, anexhalation port disposed in said port portion, a face seal configured toseal the mask over a wearer's eyes, nose and mouth, in use, saidconnecting portion of said orinasal assembly being shaped and configuredto extend through said exhalation port from the inner region to theouter region of the mask, wherein a connection mechanism is provided inor on the connecting portion of the orinasal assembly and or theexhalation port to releasably affix the orinasal assembly to the mask.